6302 9646 – 02/2004 US/CA
For Contractors
Installation, Operation and
Maintenance Manual
Sealed Combustion
Hot Water Gas Boiler
Logano GA244
CAUTION!
Before putting the boiler into operation
read this manual carefully.
WARNING !
Improper installation, adjustment,
alteration, service or maintenance can
cause injury, loss of life or property
damage. Refer to this manual. For
assistance or additional information
consult a qualified installer, service
agency or the gas supplier.
CAUTION !
The operating manual is part of the
documentation that is delivered to the
installation's operator. Go through the
information in this manual with the
owner/operator and make sure that he
or she is familiar with all the necessary
operating instructions.
Notice: This manual must be retained for future reference.
Read manual prior to installation and maintenance of the boiler
Imprint
Please read this manual carefully!
Correct installation and adjustment of the burner and the
control panel is a precondition for safe and efficient
operation of the gas boiler.
Read this manual and the specifications on the safety
label carefully before attempting to put the boiler into
operation.
We reserve the right to make any changes due to technical modifications!
2
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Table of Contents
1
Safety Considerations .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.1 Application purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2 Guideline of Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Observe the following symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2
Regulations and Guidelines
3
Dimensions and Boiler Connections
4
Packaging and Components .
5
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5.1 Transporting the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5.2 Installation Surface Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5.3 Preparations for Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
6
Boiler Water Connections .
7
Electrical Supply .
8
Gas Supply
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.1 Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.2 Installation at Higher Elevations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
9
Combustion Air and Ventilation Openings
. . . . . . . . . . . . . . . . . . . . . . . . 15
10 Installation of the Exhaust and Air Intake System
. . . . . . . . . . . . . . . . . . 17
10.1 Installation of Horizontal Wall Terminal Body . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10.2 Installation of Vertical Venting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10.3 Installation of Exhaust and Air Intake Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11 Placing the Boiler in Operation .
11.1
11.2
11.3
11.4
11.5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Lighting Instructions . . . . . . . . . . .
Operating Instructions . . . . . . . . . .
Shut off of Gas Supply . . . . . . . . .
Start-up Procedure Chart . . . . . . . .
Detailed Steps for Start-up Procedure
12 Maintenance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.1 Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.2 Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
12.3 Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
13 Parts List .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
14 Orifice Tables for High Elevations and Propane .
15 Wiring diagrams
. . . . . . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
3
1
1
Safety Considerations
Safety Considerations
Please observe the following safety instructions.
1.1
1.3
Observe the following symbols
DANGER
Application purpose
due to explosion of gas.
The GA244 gas boiler is designed for use as a hot water
heating boiler to heat water for space heating purposes
for a single and multi family houses.
1.2
WARNING!
z Note that the assembly of gas and vent
connections, the initial start-up, the
electrical connections, the
maintenance and service can only be
performed by a licensed service
contractor or technician.
Guideline of Notices
Two levels of danger are identified by the following
warning labels:
DANGER
DANGER
WARNING!
CAUTION!
Denotes a possible severely dangerous
situation where, without proper caution,
bodily injury or loss of life may result.
z Work only on gas components when
you have a license to do so.
due to electricity.
WARNING!
z Prior to doing any work on the heating
system, disconnect all electrical power
to the boiler at the emergency switch.
DANGER OF INJURY/
SYSTEM DAMAGE
z It is NOT sufficient to shut off only the
boiler control!
Denotes a possible dangerous situation
that can lead to mild to moderate bodily
injury or physical damage.
SYSTEM DAMAGE
The following symbols are used to denote a danger and
other notices:
due to improper installation.
CAUTION!
DANGER
z Observe local and state codes as well
as common industry practices during
the installation and operation of the
heating appliance.
due to electricity.
SYSTEM DAMAGE
WARNING!
APPLICATION NOTICE
Application comment for optimum use of
equipment and adjustment as well as useful
information.
CAUTION!
due to inadequate cleaning and maintenance.
z A boiler cleaning and maintenance
should be performed annually. Verify
complete system operation at the
same time.
z Correct the problem immediately to
prevent damage to the system!
We reserve the right to make any changes due to technical modifications!
4
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Regulations and Guidelines
2
2
Regulations and Guidelines
The installation must be conform to the requirements of
the authority having jurisdiction or, in the absence of
such requirements, to the latest edition of the National
Fuel Gas Code, ANSI Z223.1. In Canada, installation
must be in accordance with the requirements of
CAN/CGA B149.1 or 2 Installation Code for Gas Burning
Appliances and Equipment.
Where required by the authority having jurisdiction, the
installation must conform to the Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1.
Install CO detectors per local regulations. Boiler
requires yearly maintenance, see maintenance section
see section 12 „Maintenance“, page 35.
Operating Limits of the boiler:
Max. boiler temperature:
220°F
Max. operating pressure:
58 psi
The hot water distribution system must comply with all
applicable codes and regulations. When replacing an
existing boiler, it is important to check the condition of
the entire hot water distribution system to insure safe
operation.
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
5
3
Dimensions and Boiler Connections
3
Dimensions and Boiler Connections
B
D
A
5
6
4
C
1
3
2
Fig. 1
Rear, side and front views, measurements in inches
Pos. 1: Boiler return (1 ½“)
Pos. 2: Boiler drain connection (¾“)
Pos. 3: Gas connection (¾“)
Pos. 4: Boiler supply (1 ½“)
Pos. 5: Exhaust connection
Pos. 6: Air intake connection
Boiler
model
Heating
capacity
Air intake
connection
Exhaust
connection
Min. Relief
Valve
No. of
Burners
Watercontent
Dry
weight
MBtu/hr
Inches
Inches
lb/hr
No.
US Gal.
lbs
37
128
4
3
130
4
6.1
635
44
148
4
3
153
4
6.1
635
53
181
4
3
188
5
7.1
688
62
212
4
4
218
6
8.2
772
Table. 1 Dimensions
37
44
53
62
A
Air intake
Inches
7 3/8
B
Exhaust
Inches
17 1/2
7 3/8
17 1/2
7.9
20.9
7.9
24.4
C
D
Inches
43 3/4
Inches
43 3/4
43.3
43.3
7.25
156/182 MBTu/h
(Size 37/44)
25 6/8
25 6/8
29.1
32.7
Pressure Drop in psi
Boiler
model
Table. 2 Dimensions
1.45
0.1
1.8
17.6
68.2
Flow Rate in GPM
Fig. 2
We reserve the right to make any changes due to technical modifications!
6
Pressure drop through the boiler
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Packaging and Components
4
4
Packaging and Components
The boiler is shipped as a packaged unit complete with
jacket panels, installed gas burner tray and gas valve
and technical documents. The following components
are packaged in a separate box within the boiler
packaging:
– 1 3/4“ female boiler drain elbow
– 1 3/4“ 90° Elbow
– 1 3/4“ Relief valve
– 1 horizontal wall terminal body
Following accessories are available as well:
– Cleaning brushes
– Vertical wall terminal body
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
7
Installation
This boiler is certified for closet installations. To ensure
adequate access to the boiler during installation and
maintenance, the boiler should have a minimum space
in front of the boiler of at least 33" with the access door
open. When the access door is closed, a minimum
clearance of 2 inches in front and on the sides of the
boiler from combustibles is required (Fig.3). Maintain a
minimum clearance from combustibles of 2 inches for
the exhaust vent pipe. A 20“ top clearance is
recommended for cleaning access and is strictly
required when the boiler is placed in a fully enclosed
closet. A 2“ rear clearance is required for horizontal vent
pipe installations. The gas boiler is certified for
installation on combustible flooring. The boiler must not
be installed on carpeting.
2"
3
1
2"
Provide 2“ clearance between vent pipe and
combustible construction.
No clearance is required between wall terminal body
and combustible construction
2"
5
Installation
Fig. 3
33"
5
2"
2
Minimum clearances from combustible construction
Item. 1: Access door closed
Item. 2: Access door open
Item. 3: Exhaust vent pipe
5.1
Transporting the Boiler
z Transport the boiler to the installation site in the
shipping carton and on the pallet.
z Remove strapping and lift off carton.
z Remove the two bolts that secure boiler to the
wooden pallet.
z Lift the boiler from one side and slide to the side of
the pallet. Push a pipe under the boiler as shown in
Fig. 4 and roll boiler on several pipes to its final
location.
z Move the boiler to its final installation position.
NOTICE !
Always protect sheet metal parts, gas
pipe, burner and control panel during
handling.
z Never lift the boiler on these parts.
We reserve the right to make any changes due to technical modifications!
8
Fig. 4
Moving the boiler
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Installation
5.2
5
Installation Surface Requirements
The boiler is very heavy when filled with water. Make
sure the floor is strong enough to support the load.
5.3
Preparations for Boiler Installation
z Unpack all boxes and cartons and check that all parts
have been delivered using the packing list.
NOTICE !
Each boiler is checked and tested carefully
before leaving the factory. If there is any
damage or parts are missing, inform the
supplier without delay. Check all
packaging materials for missing
components before discarding them.
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
9
6
6
Boiler Water Connections
Boiler Water Connections
BOILER DAMAGE !
due to moisture.
DANGER!
3
z Install this boiler so that the gas ignition
system components are protected from
water (dripping, spraying, rain, etc.)
during appliance operation and service
(circulator replacement, control
replacement etc.).
SYSTEM DAMAGE !
DANGER!
due to over heating during low water
conditions.
z If this boiler is installed above radiation
level it must be provided with a low
water cut-off device either as a part of
the boiler or at the time of installation
(see Fig. 5).
2
1
2
2
4
SYSTEM DAMAGE !
DANGER!
due to high temperature differences in the
system.
z If the boiler is used in conjunction with
a refrigeration system, pipe the chilled
medium in parallel with the boiler and
install the proper valve to prevent the
chilled medium from entering the boiler.
z When the boiler is connected to heating
coils located in air handling units where
they may be exposed to refrigerated air
circulation, the boiler must be equipped
with flow control valves or other
automatic means to prevent gravity
circulation of the boiler water during the
cooling cycle.
2
2
1
2
Fig. 5
Low water cut off installation
Item. 1: Gas boiler
Item. 2: heating elements (panel radiator, baseboard, etc.)
Item. 3: system requiring low water cut off
Item. 4: system not requiring low water cut off
We reserve the right to make any changes due to technical modifications!
10
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Boiler Water Connections
z Install the 90° street elbow (Fig. 6) and the relief
valve (Fig. 6 ) on the boiler supply connection.
6
1
z Install relief valve according to ANSI/ASME Boiler
and Pressure Vessel Code, Section IV. Mount the
relief valve stem vertically. Use ¾" street elbow as
needed.
2
NOTICE !
3
4
Observe local and state codes when
installing the boiler.
FIRE DANGER !
due to hot piping.
DANGER!
z Maintain a minimum 2" clearance
between the hot water piping and
combustible walls.
Water treatment
Fig. 6
Rear view
Item. 1: Gas boiler
Item. 2: Boiler supply connection
Item. 3: Relief valve
NOTICE !
Item. 4: Boiler supply pipe
Perform a water analysis prior to filling the
boiler system. Treatment of the boiler
water may be required depending on the
analysis results.
For extremely hard water or pH value
below 7.0 consult your local water
treatment company.
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
11
7
7
Electrical Supply
Electrical Supply
The electrical connections to the boiler must be made in
accordance with all applicable local codes and the latest
revision of the National Electrical Code, ANSI/NFPA-70.
Installations should also conform with CSA C22.1
Canadian Electrical Code Part 1 if installed in Canada.
The boiler must be electrically grounded in accordance
with the requirements of the authority having jurisdiction
or, in the absence of such requirements, with the
National Electrical Code, ANSI/NFPA 70.
NOTICE
For wiring details, follow the wiring
diagrams found on page 69 and page 70.
Install an emergency switch near the boiler.
CAUTION !
due to electricity.
WARNING!
z Label all wires prior to disconnection
when servicing controls.
z Wiring errors can cause improper and
dangerous operation.
z Verify proper operation after servicing.
We reserve the right to make any changes due to technical modifications!
12
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Gas Supply
8
8
Gas Supply
8.1
Gas Connections
Determine proper size gas pipe for the installation using
Table 3 and Table 4. Do not forget the pipe fitting losses
and observe proper size of the fittings.
1
A sediment trap must be installed at the inlet of the gas
supply piping to the boiler. When local codes require, a
manual shut-off valve must be installed outside the
boiler jacket. It is recommended that a manual shut-off
valve be installed on the main gas piping to the boiler.
The gas piping must be supported external to the boiler.
2
When installing the gas supply connection, it must
comply with local regulations or, if such regulations do
not exist, with the National Fuel Gas Code, ANSI Z
223.1. In Canada, the gas supply connection must
comply with local regulations or, if such regulations do
not exist, with CSA/CGA-B149 Installation Guidelines.
3
EXPLOSION DANGER !
Fig. 7
DANGER!
The possibility for explosions exists due to
leaks in gas piping and connections.
z All gas connections must be tested for
leaks with a soap and water solution.
Length
of
pipe
(Feet)
1/2“
3/4“
1“
1 1/4“
1 1/2“
10
132
278
520
1060
1600
20
92
190
350
730
1100
Gas supply piping: rear view
Item. 1: Gas supply piping
Item. 2: Manual shut off valve
Item. 3: Sediment trap
Gas Volume Capacity
(ft3 / hr)1
30
73
152
285
590
890
40
63
130
245
500
760
50
56
115
215
440
670
75
45
93
175
360
545
100
38
79
160
305
480
150
31
64
120
250
380
Table 3 Gas Pipe Capacity for different pipe sizes
1
Maximum pipe capacity in ft³/hr, based on a specific gravity of .60
and a gas supply pressure of .5 psi or less and a pressure drop of
.3 inches W.C.
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
13
8
Gas Supply
Equivalent Length for Pipe Fittings in
feet
Steel pipe
Diameter
(in Inch)
Type of pipe fitting
90°Elbow
Tee
(flow
thru
branch)
Gate
valve
Gas
cocks
Equivalent length in feet
1/2
1.4
2.7
0.3
0.80
3/4
2.1
4.1
0.5
1.25
1
2.6
5.2
0.6
1.6
1 1/4
3.5
6.9
0.8
2.15
1 1/2
4.0
8.0
0.9
2.50
8.2
Installation at Higher Elevations
The boiler is factory set for operation with natural gas at
elevations up to 2,000 ft. The boiler must be derated for
installations above 2,000 ft. The derate is accomplished
by changing the main burner orifices. Contact your
supplier in this case to obtain the suitable high elevation
conversion kit (Natural gas or LP). Do NOT attempt to
derate the appliance without Buderus certified parts and
instructions.
Table 4 Equivalent length of pipe fittings in feet
The boiler must be isolated from the gas supply piping
system by closing its individual manual shut-off valve
during any pressure testing of the gas supply piping
system at test pressures equal to or less than ½ psi.
z The boiler and its gas connection must be leak tested
before placing the boiler in operation. Refer to
Chapter 11 "Placing the Boiler in Operation",
page 26.
Pipe joint compound (pipe dope) must be resistant to
corrosive action of liquified petroleum gases and applied
sparingly only on male threads of pipe joints.
To field convert the boiler for operation with LP gas,
please contact Buderus Hydronic Systems to obtain the
proper components. Do not convert the boiler without
the proper parts and instructions. Parts for LP
conversion are included with the documents.
We reserve the right to make any changes due to technical modifications!
14
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Combustion Air and Ventilation Openings
9
9
Combustion Air and Ventilation Openings
BOILER DAMAGE AND OPERATIONAL
FAILURES !
CAUTION!
Due to insufficient or lacking openings for
combustion air and/or ventilation of the
boiler room.
BOILER DAMAGE !
due to contaminated air.
CAUTION!
Provisions for combustion air and
ventilation are always required, regardless
whether the combustion air is taken from
the outside (sealed combustion) or inside
(room air for combustion).
Insufficient ventilation of the boiler room
can lead to high air temperatures. This
can result in boiler damage.
z Do not store and use these chemicals
in the boiler room.
z Avoid excessive dust formation and
build-up.
z Make sure that intake and exhaust
openings are sufficiently sized and no
reduction or closure of openings takes
place.
NOTICE !
z When the problem is not resolved, do
not operate the boiler.
When one expects contaminated
combustion air (near swimming pools,
chemical cleaning operations and hair
salons), sealed combustion operation is
recommended.
z Please note these restrictions and its
dangers to the operator of the boiler.
Provisions must be made for combustion air and
ventilation air in accordance with section 5.3 Air for
Combustion and Ventilation, of the National Fuel Gas
Code, ANSI Z 223.1, or applicable provisions of the local
building code.
Canadian installations must comply with CSA/CGAB149.1 and .2 Installation Codes.
We reserve the right to make any changes due to technical modifications!
z Boiler must be clear and free from
combustible materials, gasoline and
other flammable vapors and liquids,
and corrosive liquids and vapors.
Never use chlorine and hydrocarbon
containing chemicals (such as spray
chemicals, solution and cleaning
agents, paints, glues etc) in the vicinity
of the boiler.
FIRE DANGER !
due to flammable materials or liquids.
DANGER!
z Do not store flammable materials and
liquids in the immediate vicinity of the
boiler.
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
15
9
Combustion Air and Ventilation Openings
All Air from Inside the Building
The closet shall be provided with two permanent
openings communicating directly with an additional
room(s). The total input of all gas utilization equipment
installed in the combined space shall be considered in
making this determination. Each opening shall have a
minimum free area of 1 square inch per 1,000 Btu per
hour of total input rating of all gas utilization equipment
in the confined space, but no less than 100 square
inches. One opening shall commence within 12 inches
of the top, and one opening shall commence within 12
inches of the bottom of the enclosure. The minimum
dimension of air openings shall be not less than 3
inches.
All Air from Outdoor
The closet shall be provided with two permanent
openings, one commencing within 12 inches from the
top, and one commencing within 12 inches from the
bottom of the enclosure. The openings shall
communicate directly, or by ducts, with the outdoors or
spaces (crawl or attic) that freely communicate with the
outdoors. The minimum dimension of air openings shall
be no less than 3 inches.
1. Where directly communicating with the outdoors,
each opening shall have a minimum free area of 1
square inch per 4,000 Btu/hr of total input rating of
all equipment in the enclosure.
2. Where communicating with the outdoors through
vertical ducts, each opening shall have a minimum
free area of 1 square inch per 4,000 Btu/hr of total
input rating of all equipment in the enclosure.
3. Where communicating with the outdoors through
horizontal ducts, each opening shall have a
minimum free area of 1 square inch per 2,000 Btu/hr
of total input rating of all equipment in the enclosure.
4. Where ducts are used, they shall be of the same
cross-sectional area as the free area of the opening
to which they connect.
We reserve the right to make any changes due to technical modifications!
16
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Installation of the Exhaust and Air Intake System
10
10 Installation of the Exhaust and Air Intake System
A horizontal terminal body is included with every boiler.
APPLICATION NOTICE !
Materials from the following manufacturers are
approved for use for exhaust venting materials and air
intake piping:
Consult local and state codes pertaining to
special building code and fire department
requirements. Adhere to national code
requirements.
Manufacturer
Exhaust venting piping 3“/ 4“
horizontal
vertical*
Typ
Typ
Heat fab
SAF-T vent
SAF-T vent
O-flex-L
Star 34
-
Pro Tech
FasNSeal
-
Z-Flex
Z-Flex, model
SVE
-
APPLICATION NOTICE !
Observe the listed maximum lengths of
vent system, which are boiler model
dependent. The maximum permissible
lengths are listed in Table 7, page 24 to
Table 9, page 25.
Table 5 Approved exhaust vent pipe manufacturers
*
Vertical „trough the roof“ configuration is not part of the standard
boiler package.
APPLICATION NOTICE !
Install vent pipe components per
manufacturer's instructions. Observe the
listed maximum diameters of vent system,
which are boiler model dependent. Use
only 3" or 4“ (4“ for model /62 only)
stainless steel (AL29-4C) components
(e.g. 37/44 kW = 3“) for exhaust vent
piping as listed in the above table
(Table 5).
Use only 4" flexible or 4" galvanized rigid
pipe for combustion air intake piping.
The exhaust and intake air piping
components are available from your local
wholesaler. Make sure to use matching
components.
OPERATIONAL PROBLEMS !
due to strong winds.
NOTICE!
The boiler will cease to operate under
strong winds when no termination tee is
installed at the end of the venting system.
z Note that a termination tee MUST
always be installed at the end of every
horizontal venting system.
z Purchase the suitable termination tee
together with your selected vent pipe
manufacturer for best fit.
We reserve the right to make any changes due to technical modifications!
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
17
10
Installation of the Exhaust and Air Intake System
10.1 Installation of Horizontal Wall Terminal Body
Read these instructions first completely concerning
horizontal termination body installation and observe the
noted safety precautions.
The horizontal wall terminal body must be installed
through the wall according to previously mentioned
codes and/or local requirements.
z Make a 6" round opening in the outside wall at the
desired location. Refer to the information on the next
page regarding limitations of termination location.
z Remove fresh air connection end from the terminal
body and insert terminal body from the outside
through the round 6" hole in the wall (Fig. 8). Install
fresh air connection piece. Secure wall plate with 4
furnished screws to the wall.
Fig. 8
Installation of horizontal wall terminal body
z Insert a 2 or 3 foot straight exhaust pipe (Fig. 9,
Item. 2) from the outside into the wall terminal body.
Slide termination tee on exhaust pipe and seal joint
with silicone (Fig. 9, Item. 3). Orient termination tee
horizontally and observe the manufacturer's
installation instructions.
1
Fig. 9
2
3
Installation of exhaust pipe
Item. 1: wall terminal body
Item. 2: Exhaust vent pipe
Item. 3: Termination tee
We reserve the right to make any changes due to technical modifications!
18
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Installation of the Exhaust and Air Intake System
10
z Insert the vent pipe into the terminal body far enough
so that distance between the termination tee and the
wall is about 10" (Fig. 10).
z Secure both ends of the exhaust pipe through the
terminal body using the furnished locking collars.
(Fig. 10, Item. 1). Rotate collars downward and
secure set screw on locking collars (Fig. 11, Item. 2).
1
z Seal the space between vent pipe and locking collars
with silicone (Fig. 11, Item. 1).
1
A venting system that exits the structure through a
sidewall or the like, shall terminate at least 12 inches
above the ground.
The installation of a screened termination tee is
required to ensure trouble free operation and prevent
entry of foreign objects into the vent system.
2
Fig. 10
Positioning of the termination tee
Item. 1: Locking collars
Item. 2: 4“ Air intake connection
The termination of the system shall be located at least
12 inches above the maximum snow line in geographic
areas where snow accumulates.
1
No changes or modifications are allowed in the venting
system. All components must be installed in their
original condition.
The termination shall not terminate less than 7 ft above
a paved sidewalk or driveway.
The termination shall be at least 6 ft away from the
combustion air intake of any other appliance.
Room air only:
The termination shall be at least 3 ft away from gas utility
meter, service regulator or the like (for room air
applications only).
The termination shall terminate at least 4 ft below, 4 ft
horizontally from, or 1 ft above any door, window, or
gravity air inlet into any building.
We reserve the right to make any changes due to technical modifications!
2
Fig. 11
Vent pipe locking collars
Item. 1: Seal space with beads of silicone
Item. 2: Set screws
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
19
10
Installation of the Exhaust and Air Intake System
10.2 Installation of Vertical Venting System
NOTICE !
Only venting components and concentric
vent pipe manufactured by Heat-Fab type
SAF-T Vent can be used for vertical
venting applications. Please contact
Buderus Hydronic Systems,Inc. for
assistance in selecting proper venting
components.
1
2
Follow all instructions concerning assembly of the
individual venting components. Follow in particular the
instructions furnished by the vent pipe manufacturer.
3
3
The combustion air is ducted in using a concentric 6" or
7“ pipe configuration in a vertical venting application
Fig. 12.
4
NOTICE !
Fig. 12
Ensure that a condensate drain is always
installed at the boiler exhaust connection.
Item. 1: Wall terminal body
Vertical venting system (sealed combustion)
Item. 2: Fire stop plate
Item. 3: Support of vent system
Item. 4: Condensate drain
Observe the vent extension above the roof line as
shown in Fig. 12.
The maximum length of the concentric "through the roof"
venting is 10 ft. (see Fig. 12).
1
2
Observe the maximum length of the entire vent system
including the concentric piping based on Table 7,
page 24 to Table 9, page 25.
The concentric piping permits a zero clearance to
combustibles. Note, however, that the exhaust vent
pipe leading up to the concentric piping requires a 2"
minimum clearance to combustibles.
3
3
Install fire stop plates when penetrating the roof (Fig. 12,
Item. 2).
4
Fig. 13
Vertical venting system (Room air only)
Item. 1: Roof termination
Item. 2: Fire stop plate
Item. 3: Support for vent system
Item. 4: Condensate drain
We reserve the right to make any changes due to technical modifications!
20
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Installation of the Exhaust and Air Intake System
10
10.3 Installation of Exhaust and Air Intake Piping
Installation of exhaust vent pipe at the boiler
(Fig. 15, Item. 2)
z Install a condensate drain at the rear of the boiler
(Fig. 14).
3
4
NOTICE !
Always install a condensate drain as the
first component of the exhaust system.
2
z Place a ¼" wide silicone bead (Fig. 14, Item. 1) on
the boiler exhaust collar. (Use silicone with a 500 F
temperature rating, G.E. 106 or equivalent).
z Slide condensate drain on exhaust collar (Fig. 14,
Item. 4) and secure with the furnished pipe clamp
(Fig. 14, Item. 3). (Heat-Fab condensate drain will fit
around outer collar, other condensate drains fit on
inner collar.)
z Place a silicone bead around the clamp (Fig. 14,
Item. 2) and spread out to ensure an air tight seal.
1
Fig. 14
Condensate drain
Item. 1: Silicone bead
Item. 2: Silicone bead
Item. 3: Gear clamp
Item. 4: Condensate drain
Installation of the air intake pipe (Fig. 15, Item. 1) at
the boiler
2
1
Follow the same installation procedure as with the
exhaust piping. Do not install a condensate drain here.
Fig. 15
Rear view of the boiler
Item. 1: Air intake connection
Item. 2: Exhaust connection
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
21
10
Installation of the Exhaust and Air Intake System
DANGER !
due to possible intake of exhaust gases.
WARNUNG!
4
z Connect the venting system only to a
single appliance.
4
1
z Venting of an additional appliance
could cause serious injury or loss of life.
2
z The venting system shall not be routed
into, through or within any other vent,
such as an existing masonry or factory
built chimney flue.
3
FIRE DANGER !
WARNUNG!
due to minimal distances between vent
pipe and combustible materials.
z Provide 2“ clearance between vent
pipe and combustible construction.
Fig. 16
Horizontal venting system
z No clearance is required between wall
terminal body and combustible
construction.
Item. 2: Termination tee
Item. 1: Wall terminal body
Item. 3: Condensate drain
Item. 4: Support bracket of venting system
The vent pipe must be properly supported. Vertical runs
must use firestops as lateral supports at each ceiling
level and at least one support collar at the base of the
vertical run.
1
Horizontal runs require a loose fitting metal strap or
similar support every 4 ft and at every elbow and pipe
connection joint.
2
Make sure never to penetrate the piping components
when securing the straps or installing the various vent
components. When cutting pipes to length, file the cut
length smooth. Do not cut off the female end of the vent
pipe.
3
3
All horizontal runs must be sloped down towards the
boiler at least ¼" per foot. In the case of multiple
horizontal runs, slope all runs towards the boiler to
prevent moisture build-up in the system.
4
Fig. 17
Vertical venting system
Item. 1: Roof termination
Item. 2: Fire stop plate
Item. 3: Support bracket of venting system
Item. 4: Condensate drain
We reserve the right to make any changes due to technical modifications!
22
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Installation of the Exhaust and Air Intake System
10
The vent system will be under positive pressure. Check
all seams for gas tightness. Allow 24 hours for silicone
to cure before operating the boiler.
DANGER !
due to possible intake of exhaust gases.
DANGER!
z When any of the previous installation
procedures are completed be sure to
go over the entire system to make sure
all joints are secure and sealed
correctly.
z Check all seams and joints for gas
tightness.
z It is required to have the entire system
checked by a qualified inspector at
least annually following initial
installation.
NOTICE !
Table 6 shows the equivalent length for
each 45° and 90° elbow for each listed
vent pipe manufacturer of each GA244
model boiler.
Equivalent length of vent pipe / air intake pipe in ft.
model 37
model 44
model 53
model 62
Manufacturer
Typ
45°
90°
45°
90°
45°
90°
45°
90°
heat fab
SAF-T vent
4.5
9
4.5
9
5
10
3.5
7
O-flex-L
Star 34
5
10
5
10
5
10
5
10
Pro Tech
FasNSeal
5
10
5
10
5
10
4
8
Z-Flex
Z-Flex
4.5
9
4.5
9
5
10
4
8
Table 6 Equivalent length of vent pipe / air intake pipe
NOTICE !
NOTICE!
The follwing maximum equivalent length of
exhaust pipe (Table 7, page 24 and
Table 9, page 25) represents the maximum
equivalent length of exhaust vent pipe or air
intake pipe only, without condensate drain
tee, vent piping within the termination body
and length of the termination tee. Note that
we only need to be concerned about the
longest run; do not combine intake and
exhaust piping.
We reserve the right to make any changes due to technical modifications!
To increase overall vent length, use a
couple of 45° elbows on air intake piping
and run the intake piping at an angle.
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
23
10
Installation of the Exhaust and Air Intake System
10.3.1 Sealed Combustion and Horizontal Venting
Combustion air from outside the building.
Sealed Combustion Configuration
Boiler
model
Exhaust vent pipe/
Air intake pipe
37
50 feet
44
40 feet
53
50 feet
62
50 feet
1
Table 7 Maximum equivalent length of exhaust vent pipe or
air intake pipe for horizontal venting (Fig. 18)
2
10.3.2 Room Air Configuration and Horizontal
Venting
Combustion air from boiler room.
Fig. 18
(No air intake pipe needed)
Horizontal sealed combustion vent system
Item. 1: Exhaust vent pipe 3“
Item. 2: Air intake pipe 4“
Room Air Configuration
Boiler
model
Exhaust vent pipe
37
50 feet
44
40 feet
53
50 feet
62
50 feet
2
Table 8 Maximum equivalent length of exhaust vent pipe
(for horizontal venting Fig. 19)
Fig. 19
1
Horizontal room air venting system
Item. 1: Exhaust vent pipe 3“
Item. 2: Combustion air from room
We reserve the right to make any changes due to technical modifications!
24
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Installation of the Exhaust and Air Intake System
10
10.3.3 Sealed Combustion and Vertical Venting
Combustion air from outside the Building.
Sealed Combustion Configuration
Boiler
model
Exhaust vent pipe/
Air intake pipe
37
40 feet (max. 10 feet co-axial)
44
40 feet (max. 10 feet co-axial)
53
50 feet (max. 10 feet co-axial)
62
50 feet (max. 10 feet co-axial)
1
Table 9 Maximum equivalent length of exhaust vent pipe or
air intake pipe for vertical venting (Fig. 20)
NOTICE !
2
Do not exceed 10 ft concentric piping with
vertical termination.
Fig. 20
Vertical sealed combustion vent system
Item. 1: Exhaust vent pipe 3“ (models 37, 44 and 53)
Item. 2: Air intake pipe 4“
10.3.4 Room Air Configuration and Vertical Venting
Room Air Configuration
Boiler
model
Exhaust vent pipe
37
40 feet
44
40 feet
53
50 feet
62
50 feet
1
Tab. 10 Maximum equivalent length of exhaust vent pipe
for vertical venting (Fig. 21)
NOTICE !
Vertical concentric piping is only required
for the length of the roof penetration.
Combustion air can be drawn then directly
from the boiler room.
We reserve the right to make any changes due to technical modifications!
Fig. 21
Vertical vent system for room air configuration
Item. 1: Exhaust vent pipe 3“ (models 37, 44 and 53)
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
25
11
Placing the Boiler in Operation
11 Placing the Boiler in Operation
Safe lighting and other performance criteria were met
with the gas manifold and control assembly provided on
the boiler when the boiler underwent factory tests
specified in ANSI Z 21.13 and CSA 4.9.
2
DANGER
due to electricity when control is opened.
WARNUNG!
z Before opening the boiler: ensure all
electric power has been disconnected
with the main shut-off switch.
z Secure the system from someone
accidentally turning on the power.
1
1. Turn off all electric power to the appliance and set
the thermostat to lowest setting.
1
Fig. 22
Remove the boiler front access panel
Item. 1: Screws
Item. 2: Boiler front jacket panel
2. Check the combustion air inlet, exhaust vent and
ventilation openings.
6
5
3. Fill the boiler system with water and purge the air
from the boiler and radiators.
7
4. Remove the screws from the boiler front access
panel (Fig. 22, Item. 1) and remove the boiler front
access panel (Fig. 22, Item. 2).
4
5. Remove side cover plate screws (Fig. 23, Item. 1)
from the right side jacket panel (Fig. 23, Item. 3) and
then remove the side cover plate (Fig. 23, Item. 2).
3
Testing for leaks
6. Open the main gas supply shutoff valve.
7. Test the equalizing hose (Fig. 23, Item. 7) on the
side of the gas valve connection (Fig. 23, Item. 4)
and on the side of the burner box connection
(Fig. 23, Item. 5) for leaks.
2
1
1
Fig. 23
Removal of side cover plate
Item. 1: Screws
8. Check if the pressure test port on the burner box
(Fig. 23, Item. 6) is closed.
9. Test the gas piping on the side of the gas control for
leaks (Fig. 24) by applying a soap and water
solution. If no leaks are found go to step 10. If any
leaks are found, shut off the main gas piping shut-off
valve.
We reserve the right to make any changes due to technical modifications!
26
Item. 2: Side cover plate
Item. 3: Right side jacket panel
Item. 4: Connection port for equalizing hose, gas valve side
Item. 5: Lower testing port from the burner to the gas valve
Item. 6: Pressure test port, burner box
Item. 7: Equalizing hose
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Placing the Boiler in Operation
11
10. Repair leaks and repeat step 9.
11. Remove the manifold pressure tapping plug
(Fig. 24, Item. 3) from the gas control, install a test
fitting (Fig. 23, Item. 6) and hook up a manometer
between pressure tapping plug (Fig. 24, Item. 3)
(overpressure) and the pressure test port (burner
box) (negative pressure) (Fig. 24, Item. 6) so that
the line pressure can be checked. Check manifold
pressure. Set the manifold pressure according the
values in Table 11, page 29. If corrections are
necessary see Table 11, page 29.
12. Open main gas piping shutoff valve and measure
the supply pressure to the boiler. The supply
pressure must be between 4.7 and 10.5 inches
water column (WC) for natural gas or 11 and 13
inches water column for propane gas. If the
pressure is not between 4.7 and 10.5 inches WC for
natural gas or between 11 and 13 inches WC for
propane gas, call your service technician or gas
supplier.
2
1
4
Fig. 24
3
Gas control
Item. 1: Gas control knob (set to “ON“)
13. Follow the lighting instructions below.
Item. 2: Test port screw for gas supply measurement
Item. 3: Test port screw for manifold pressure measurement
Item. 4: Pilot tubing
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
27
11
Placing the Boiler in Operation
11.1 Lighting Instructions
For your safety, read these instructions before
lighting.
WARNING !
due to not follow these instructions.
WARNING!
z If you do not follow these instructions
exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
C) Use only your hand to turn the gas control knob.
Never use tools. If the knob will not turn by hand,
don't try to repair it, call a qualified service
technician. Force or attempted repair may result in
a fire or explosion.
D) Do not use this appliance if any part has been under
water. Immediately call a qualified service
technician to inspect the appliance and to replace
any part of the control system and any gas control
which has been under water.
z Follow these operating instructions.
DANGER !
What to do if you smell gas:
DANGER!
z No open fire! Do not smoke!
z Avoid formation of sparks! Do not
touch any electric switch, phone,
electric plug or bell!
z Shut off main gas supply.
z Open windows and doors!
z Notify all occupants!
z Leave the building!
z Immediately call your gas supplier,
heating contractor or fire department
from a phone outside the building!
A) This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to light
the pilot by hand.
B) Check for smell of gas around the appliance area.
Be sure to smell next to the floor because some gas
is heavier than air and will settle on the floor.
We reserve the right to make any changes due to technical modifications!
28
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Placing the Boiler in Operation
11.2
11
Operating Instructions
STOP! Read the safety precautions on page 28 of this
manual.
1. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas, STOP! Follow "B" in the safety information on
page 28. If ou do not smell gas, go to the next step.
2. Locate the pilot assembly by looking through the
access viewing port (Fig. 25, Item. 1) on the burner
front plate.
3. Turn the gas control knob (Fig. 26, Item. 1)
counterclockwise to position "ON".
4. Turn on the electrical power to the application.
1
5. Set the thermostat to the desired setting to activate
the boiler (Thermostat adjustment should be at least
10 °F above the room temperature).
Fig. 25
Burner tray box
Item. 1: Access viewing port
6. The ignition control should initiate sparking at the
pilot. The pilot should light and then the main
burners should light. If the main burners do not light,
shut off the main gas piping shutoff valve. Shut off
all electric power to the appliance and call your
service technician or gas supplier.
2
7. If the main burners light, then the gas fittings, union
and orifices must be tested for leaks with a soap and
water solution. If no leaks are found then go to step
9. If any leaks are found, turn off gas control knob
(Fig. 26, Item. 1) clockwise to "OFF". Turn off all
electric power to the appliance, set the thermostat to
lowest setting.
5
1
8. Repair leaks. Repeat steps 1 through 7.
9. Check the supply pressure while the boiler is
running. Pressure must be between 4.7 and 10.5
inches WC for natural gas. Pressure must be
between 11 and 13 inches WC for propane gas.
Record supply pressure on the boiler start-up
procedure on page 33.
4
Fig. 26
3
Gas control valve
Item. 1: Gas control knob (set to “ON“)
Item. 2: Test port screw for gas supply measurement
Item. 3: Test port screw for manifold pressure measurement
Item. 4: Protective screw for pilot pressure adjustment
Item. 5: Protective screw for manifold pressure adjustment
10. Check manifold pressure. Set the manifold pressure
according the values in Table. 11. To adjust the
manifold pressure (Fig. 26, Item. 5), remove the
capscrew from the gas control and remove the hose
from the manometer to the burner box test port
(Fig. 23, Item. 6). Turn the pressure regulating
adjusting screw clockwise to increase, or
GA244
Natural Gas
[inch W.C.]
Propan
[inch W.C.]
37
3.77
8.03
44
3.65
7.63
53
3.73
8.11
62
3.77
6.15
Table. 11 Required manifold pressure
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
29
11
Placing the Boiler in Operation
counterclockwise to decrease the manifold
pressure. This adjustment must be made while the
boiler is in operation.
11. After adjustment, record pressure on the form on
page 33, and install the capscrew (Fig. 26, Item. 5)
on the gas control valve. Shut the test port screw for
manifold pressure measurement.
12. Observe the pilot flame (Fig. 27, Item. 2) through
viewing port (Fig. 27, Item. 1) in the burner cover
plate. The flame should envelop the flame sensor
1/2 to 1 1/2 inch, see (Fig. 27, Item. 1). If the pilot
flame is satisfactory then go to step 13. If the pilot
flame is too small or too large, adjust the pilot using
pilot adjustment screw. Turn the inner adjustment
screw (Fig. 26, Item. 4) clockwise to decrease, or
counterclockwise to increase the pilot flame. After
adjustment, replace the cover screw (Fig. 26,
Item. 4) and tighten firmly.
2
1
Fig. 27
Pilot flame
Item. 1: 1/2“ to 1 1/2“
Item. 2: Pilot flame
13. Observe the main burner flame (Fig. 28, Item. 1)
through the viewing port (Fig. 25, Item. 1) in the
burner cover plate. The flame should have a
smooth, firm contour and must be mostly blue color.
If the main burner flame is satisfactory then go to
step 14. If the main burner flame is lazy, yellow, or
lifting off the burners, turn the gas control knob
(Fig. 26, Item. 1) to "OFF". Shutt off the main gas
supply shut-off valve. Disconnect all electric power
to the appliance and call your technician or gas
supplier.
1
14. The ignition safety shut-off must be tested. Test the
safety shut-off by shutting off the main gas piping
shutoff valve.
The main burner and pilot flame (Fig. 27, Item. 2)
will extinguish. Within six (6) seconds the gas control
main gas solenoid should close and make an
audible sound. The ignition will spark.
Fig. 28
Main gas burner
Item. 1: Main burner flame
After 90 seconds, the module should go into lock out
mode and the spark should stop. Disconnect the
electric power to the appliance. Open the main gas
shutoff valve. Turn on the electric power to the unit.
A normal operating sequence should occur. If the
gas control functions satisfactorily then go to step
15. If the gas control does not function satisfactorily,
immediately turn the gas control knob (Fig. 29,
We reserve the right to make any changes due to technical modifications!
30
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Placing the Boiler in Operation
11
Item. 1) clockwise to "OFF".
Shut off the main gas piping shut-off valve.
Disconnect all electric power to the appliance and
call your service technician or gas supplier.
15. Turn the gas control knob (Fig. 29, Item. 1)
counterclockwise to "OFF".
16. Shut the main gas piping shut-off valve.
17. Turn off electric power to the appliance, and set the
thermostat to the lowest setting.
18. Remove the pressure test fittings from the gas
supply and manifold pressure tabs in the gas control
and replace the plugs.
19. Repeat steps 1 to 6, and 13 to place the appliance
back in operation. Check the plugs in the gas control
with a soap and water solution. If no leaks are found
go to step 21. If any leaks are found, shut off the
main gas piping shut-off valve and turn off all electric
power to the appliance and turn the gas control knob
clockwise to "OFF" (Fig. 29, Item. 1).
20. Repair leaks. Open the main gas shutoff valve and
repeat step 19.
1
Fig. 29
Gas control valve
Item. 1: Gas control knob
21. Wash off the soap and water solution used to test for
leaks to ensure no corrosive effects from the soap.
22. Check the high limit aquastat operation to ensure
that it shuts off the boiler when the boiler water
temperature reaches the setpoint of the aquastat.
Records fill in on form found on page 33.
23. Replace the front boiler jacket panel.
We reserve the right to make any changes due to technical modifications!
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
31
11
Placing the Boiler in Operation
11.3 Shut off of Gas Supply
1. Set thermostat to its lowest setting.
2. Turn off all electric power to the appliance if service
is to be performed.
3. Remove the front boiler jacket panel, see Fig. 22,
page 26.
4. Turn gas control knob (Fig. 29, Item. 1) clockwise to
“OFF“. Do not force.
5. Replace the front boiler jacket panel.
We reserve the right to make any changes due to technical modifications!
32
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Placing the Boiler in Operation
11
11.4 Start-up Procedure Chart
Record the following information during initial start-up of
the boiler. This record will save as a reference for yearly
inspections.
Please consider the instructions on the following pages.
Putting into operation
Remarks or measurements
Natural Gas
Propane
1.
Note type of gas.
2.
Check combustion air and ventilation openings and flue connection
3.
Check boiler for correct orifices, see Table. 12 below
4.
Fill boiler with water and purge air from the system.
5.
Measure gas inlet pressure in inches water colum.
––––––––––––––––––– inches
W. C.
6.
Check manifold pressure and adjust if necessary.
––––––––––––––––––– inches
W. C.
7.
Leakage test during operation
Check pilot and main burner flames and vent system operation.
8.
Take stack measurements; see instructions on following pages.
Gross stack flue gas temperature tA
––––––––––––––––––– °F
Ambient air temperature tL
––––––––––––––––––– °F
Net stack flue gas temperatiure tA - tL
––––––––––––––––––– °F
Carbon dioxide content stack (CO2) or oxygen content (O 2)
––––––––––––––––––– %
Flue gas loss qA
––––––––––––––––––– %
Carbon monoxide content (CO), airfree in ppm
––––––––––––––––––– ppm
9.
Check the high limit aquastat operation
10.
Replace the boiler front jacket panel
11.
Inform owner/sign and hand over the technical documents
12.
Installing Contractor
Signature:__________________
Owner:
Signature:__________________
Main orifice Size
Boiler model
37
44
53
62
Natural gas
3.00
3.25
3.20
3.15
Propane gas
1.95
2.15
2.10
2.20
Table. 12 Main orifice sizes
We reserve the right to make any changes due to technical modifications!
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
33
11
Placing the Boiler in Operation
11.5 Detailed Steps for Start-up Procedure
11.5.1 Taking flue gas measurements
z Record all measurements on page 33.
z Take sampling probe to the outside of the building.
Under no circumstances drill a hole in the venting
system!
z Take all flue gas samples from this location.
z Allow boiler to run for 5 minutes before taking
measurements.
Carbon monoxide content
The measured carbon monoxide content must be
converted according to the following formula to an air
free state and entered in the record. CO2 max for
natural gas is approx. 12 % (propane, approx. 14 %)
CO airless = CO2 max./CO2 measured x CO measured
In an airless state, CO measurements must be lower
than 400 ppm or .04 % volume. Measurements around
or greater than 200 ppm indicate an erroneous burner
setting, dirt in the gas burner or heat exchanger, or
defects in the burner.
z The problem must be correctly immediately.
11.5.2 Carbon dioxide content
z If the carbon dioxide content is less than 5 % or more
than 9 % for natural gas or less than 6 % or more than
10 % for propane, check the setting of the air inlet
plate and the integrity of the complete venting system
(Fig. 18a).
Inform the owner/operator and hand over the
technical documents.
Make the owner/operator familiar with the entire installation and the operation of the boiler. Sign the form with
the owner on page 35 and turn over the documents to
the owner (page 33).
11.5.3 Flue gas loss
SYSTEM DANGER !
Flue gas loss can be calculated with the following
formula:
due to frost.
CAUTION!
qA = ((tA – t L) x A) /CO2 in %
The heating system can freeze up if the
system is shut down for the winter.
qA = flue gas loss
tA = gross flue gas temperature in F
tL = ambient air temperature in F
A = see Table 12
CO2 = carbon dioxide in %
z Protect the heating installation from
freezing.
z Drain water from the boiler, heating
system and hot water tank to prevent
freezing.
Values for A and B are listed below:
A
Natural gas
0.62
Propane gas
0.53
Table. 13
We reserve the right to make any changes due to technical modifications!
34
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Maintenance
12
12 Maintenance
12.1 Maintenance Record
Maintenance should only be performed by a trained technician on a yearly basis.
Check off the maintenance items once they are completed and enter the measurements where indicated.
Read and follow the maintenance instructions on the following pages.
Maintenance items
Date:
Date:
Date:
1.
Examine venting system, including
combustion, ventilation and intake air
2.
Inspect boiler
3.
Inspect gas burner
4.
Clean boiler
5.
Clean gas burner
6.
Measure gas supply pressure
––––––– inches
W. C.
–––––––inches
W. C.
–––––––inches
W. C.
7
Measure manifold pressure
––––––– inches
W. C.
–––––––inches
W. C.
–––––––inches
W. C.
8.
Check for air tightness of boiler
9.
Check pilot and main burner flames
10:
Check inducer motor operation
11.
Take measurements
Gross flue gas temperature tA
–––––––––––––
°F
––––––––––––– °F
––––––––––––– °F
Air temperature tL
–––––––––––––
°F
––––––––––––– °F
––––––––––––– °F
Net flue gas temperature tA - tL
–––––––––––––
°F
––––––––––––– °F
––––––––––––– °F
Carbon dioxide content (CO2) in %
or oxygen content (O2)
–––––––––––––
%
––––––––––––– %
––––––––––––– %
Flue gas loss qA, see page 36
–––––––––––––
%
––––––––––––– %
––––––––––––– %
Carbon monoxide content (CO), airfree
–––––––––––––
ppm
––––––––––––– ppm
––––––––––––– ppm
12.
Check high limit aquastat operation
13.
Check boiler area for combustible materials,
gasoline and other flammable or corrosive liquids.
14.
Confirmation of maintenance
Confirmation by service provider
(Signature)
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
35
12
Maintenance
Date:
Date
Date
Date
Date
––––––– inches
W. C
–––––––inches
W. C
–––––––inches
W. C
–––––––inches
W. C
–––––––inches
W. C
––––––– inches
W. C
–––––––inches
W. C
–––––––inches
W. C
–––––––inches
W. C
–––––––inches
W. C
–––––––––––––
°F
––––––––––––– °F
––––––––––––– °F
––––––––––––– °F
––––––––––––– °F
–––––––––––––
°F
––––––––––––– °F
––––––––––––– °F
––––––––––––– °F
––––––––––––– °F
–––––––––––––
°F
––––––––––––– °F
––––––––––––– °F
––––––––––––– °F
––––––––––––– °F
–––––––––––––
%
––––––––––––– %
––––––––––––– %
––––––––––––– %
––––––––––––– %
–––––––––––––
%
––––––––––––– %
––––––––––––– %
––––––––––––– %
––––––––––––– %
–––––––––––––
ppm
––––––––––––– ppm
––––––––––––– ppm
––––––––––––– ppm
––––––––––––– ppm
We reserve the right to make any changes due to technical modifications!
36
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Maintenance
12
12.2 Maintenance Procedure
Maintenance should only be performed by a qualified
service technician. When replacing parts, use only
Buderus authorized components. Maintenance should
be done on a yearly basis. Results of the inspection
must be recorded on the form provided on page 35.
Comments below refer back to points of maintenance
record list on page 35.
1.: Examination of venting system, including
combustion, ventilation and intake air components
Inspect the venting system including the combustion,
ventilation and intake air openings. Any repairs
identified must be corrected immediately.
Ensure that there is no obstruction of combustion, air intake and ventilation air flow.
2.: Inspection of boiler
DANGER !
DANGER!
due to electric power with opened boiler
jacket panel.
z Before removing the boiler front jacket
panel: disconnect electric power to
appliance or turn off power switch to the
appliance.
z Protect the system against accidental
power up.
We reserve the right to make any changes due to technical modifications!
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
37
12
Maintenance
Removal of gas burner:
1. Shut-off main gas piping shut off valve.
2. Remove the screws from the boiler front access
panel (Fig. 30, Item. 1) and remove the boiler front
access panel (Fig. 30, Item. 2).
2
1
1
Fig. 30
Removal of boiler jacket front panel
Item. 1: Screws
Item. 2: Boiler jacket front panel
3. Turn the gas control knob (Fig. 31, Item. 1)
counterclockwise to "OFF". Do not force.
DANGER
due to explosion of the gas.
WARNING!
z Wait five (5) minutes to clear out any
gas. Then smell for gas, including near
the floor. If you smell gas, STOP!
Follow "B" in the safety information on
page 28. If ou do not smell gas, go to
the next step.
1
Fig. 31
Gas control valve
Item. 1: Gas valve knob (set to “ON“)
We reserve the right to make any changes due to technical modifications!
38
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Maintenance
12
4. Disconnect gas pilot line (Fig. 32, Item. 1) from gas
control (Fig. 32, Item. 9)
5. Label the flame roll-out switch wires (Fig. 32,
Item. 2) and disconnect the wires from the flame
roll-out switch (Fig. 32, Item. 3).
9
6. Disconnect gas control valve wires (Fig. 32, Item. 4)
from the gas control valve (Fig. 32, Item. 7).
1
2
3
4
5
6
7
7. Secure gas supply pipe (Fig. 32, Item. 5) with a
cable or rope around the gross control bracket.
8. Disconnect union (Fig. 32, Item. 6) between the gas
valve (Fig. 32, Item. 7) and the main gas supply pipe
(Fig. 32, Item. 5). Place the gasket from the union in
a safe position.
8
DANGER !
WARNING!
due to electricity .
Fig. 32
z Label all wires prior to disconnection
when servicing controls. Wiring errors
can cause improper and dangerous
operation.
Item. 1: Ignition cable
z Verify proper operation after servicing.
Front view
Item. 2: Flame roll-out switch cable
Item. 3: Flame roll-out switch
Item. 4: Gas valve cable
Item. 5: Gas supply pipe
Item. 6: Union
Item. 7: Gas valve
Item. 8: Air intake hose
Item. 9: Gas control module
9. Loosen air intake hose (Fig. 32, Item. 8) and
remove from burner tray box
10. Remove the nuts (Fig. 33, Item. 1) that secure the
burner tray to the boiler and remove entire burner
tray (Fig. 33, Item. 3).
11. Remove inducer motor when boiler requires
cleaning; or go to 5.: “Cleaning of the gas burner“,
page 42.
1
3
Fig. 33
2
1
Removal of the gas burner tray
Item. 1: Nuts
Item. 2: Union
Item. 3: Gas burner tray assembly
We reserve the right to make any changes due to technical modifications!
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
39
12
Maintenance
Removal of inducer.
1. Remove both screws (Fig. 34, Item. 1) on top rear
jacket cover (Fig. 34, Item. 2).
2. Remove top rear jacket cover (Fig. 34, Item. 2).
2
1
1
Fig. 34
Removal of the Top rear jacket cover
3. Remove the screws from the fan blower box and
remove the cover plate from the fan blower box.
4. Pull off the electrical connections.
5. Remove the screws from the flue collector.
2
6. Remove the screws (Fig. 35, Item. 3) that secure
the sheet metal blower base.
1
3
7. Check blower wheel for dirt and clean when
necessary.
4
8. Clean the boiler heat exchanger when necessary,
see 4.: “Cleaning the boiler“, page 41.
Fig. 35
Removal of the inductor
Item. 1: Fan blower box cover plate
Item. 2: Screws
Item. 3: Screws
Item. 4: Sheet metal blower base
We reserve the right to make any changes due to technical modifications!
40
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Maintenance
12
3.: Inspection of the gas burner
1. Check burner box, air intake hose and burner tubes
for contamination, and clean components when
necessary, see 5.: “Cleaning of the gas burner“,
page 42.
2. Check air intake hose for damage and replace when
necessary.
4.: Cleaning the boiler
The cleaning of the heat exchanger of the boiler can be
achieved with brushes and/or a wet spray cleaning.
a) Brush cleaning:
1. Brush out from the top the heating passages.
b) Spray cleaning / combined cleaning:
1. Select proper cleaning agent based nature of buildup. (Soot or corrosive build-up).
2. Follow manufacturer's instructions with respect to
use of cleaning unit and cleaning agent. It may be
that the application of the cleaning agent is different
that described here.
3. Heat boiler to a temperature of about 122° F.
4. Shut off main gas piping shutoff valve.
Fig. 36
Cleaning with a brush
Fig. 37
Spray cleaning of the boiler
5. Disconnect electric power to the appliance.
6. Remove gas burner tray and inducer blower (Refer
to 2. "Inspection of the boiler"), see page 37.
7. Cover controls with aluminum foil; avoid spraying on
gas and electrical controls.
8. Put dry absorbing rags on top of board insulation in
the bottom of boiler.
9. Spray the heating passages evenly from the top with
the cleaning agent.
* Cleaning accessories= please order separate.
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
41
12
Maintenance
Spray only in the heating passages!
10. Let the cleaning agent soak for about 15 minutes.
11. Remove dry absorbing rags from the bottom of the
chamber.
12. Remove aluminum foil from controls.
13. Install inducer and gas burner tray (Refer to next
section: "Reassembly of removed components").
14. Bring boiler to maximum temperature. (Set
Logamatic control, if present, to manual setting).
Remove gas burner tray after the boiler has dried
out.
15. A thorough brushing of the heating surfaces is
recommended. This requires a disassembly and
reassembly as previously discussed.
16. Clean burner chamber and insulation board in the
bottom of the chamber.
17. Vent the boiler room thoroughly.
5.: Cleaning of the gas burner
1. Remove burner tray cover plate screws from the
burner tray box.
1
2. Remove ignition cable (Fig. 38, Item. 4) from pilot
burner assembly (Fig. 38, Item. 1).
3. Loosen the pilot gas line (Fig. 38, Item. 3) on the
pilot burner (Fig. 38, Item. 1).
4. Remove pilot gas orifice (Fig. 38, Item. 2) and blow
out to clean.
2
5. Dip burner tubes into water with dishwashing
cleaning agent and brush off. Ensure that insulation
does not get wet.
6. Rinse the burner rods with a stream of water: when
doing so, hold the gas burner in such a way that the
water penetrates into all burner perforations and
runs out again through the Venturi tubes.
3
4
7. Remove the rest of the water by shaking the burner
tubes.
Fig. 38
8. When necessary, clean burner box housing and air
intake hose.
Item. 2: Pilot gas orifice
9. Check the burner perforations for free passages;
remove any water from the perforations. If any
perforations are damaged, the burner tray must be
replaced.
Item. 4: Ignition cable
We reserve the right to make any changes due to technical modifications!
42
Pilot burner assembly
Item. 1: Pilot burner assembly
Item. 3: Pilot gas line
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Maintenance
12
Reassembly of removed components
1. Reassemble and install the pilot burner assembly
and gas burner in reverse order from its removal.
Make sure that sheet metal burner box cover is
assembled properly in the gasketed seal.
10
2. Reassemble and install the gas burner in reverse
order from its removal. Tighten the four (4) burner
tray nuts evenly (see page 38 to page 39.)
9
1
3. Secure union between gas valve (Fig. 39, Item. 7)
and gas supply pipe (Fig. 39, Item. 5) and make
sure to install the gasket, discussed in step 8 on
page 39.
8
4. Replace gaskets and seals when necessary.
2
3
4
5
6
7
5. Reconnect wires to the flame roll-out switch (Fig. 39,
Item. 2).
6. Remove rope or wire that secured the gas piping
(Fig. 39, Item. 5) as discussed in step 7 on page 39.
7. Reconnect the ignition cable (Fig. 39, Item. 1) to
ignition control box (Fig. 39, Item. 12).
8. Install the inducer by reversing removal process,
see, page 40.
9. Take to boiler in operation according section 11
"Placing the Boiler in Operation", page 26 to
page 34.
10. Take flue measurements according to the procedure
on section 11.5.1 "Taking flue gas measurements",
page 34.
Fig. 39
Front view
Item. 1: Ignition cable
Item. 2: Flame roll-out switch cable
Item. 3: Flame roll-out switch
Item. 4: Gas valve cable
Item. 5: Gas supply pipe
Item. 6: Union
Item. 7: Gas valve
Item. 8: Air intake hose
Item. 9: Gas control module
Item. 10: Aquastat
We reserve the right to make any changes due to technical modifications!
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
43
12
Maintenance
11. Verify proper operation of the aquastat (Fig. 39,
Item. 10).
12. Test low water cut-off operation, if present.
13. Check boiler surroundings for irregularities. Its
surroundings must be free of flammable materials,
gasoline or other flammable or corrosive gases and
liquids.
14. Confirm the maintenance record by filling out all
listed items. Sign the maintenance record and hand
it to the owner/operator of the boiler.
We reserve the right to make any changes due to technical modifications!
44
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Maintenance
12
12.3 Trouble Shooting Guide
Required tools: electrical diagram on page 69 and a
multimeter with 120 VAC and 24 VAC scales.
Start
• Checking of aquastat and transformer.
Turn gas supply off.
Supply power to the boiler
LED light up on boiler
(aquastat).
NO
* Check for line voltage (120 V) at N and L at plug X1.
If no voltage present, check incoming line voltage.
• * Check if 120 V at L1/L2 and L1X/L2X on aquastat.
If no 120 V present, check wiring.
If wiring is fine, replace aquastat.
• * Check for 24 V between terminals C and R on aquastat
If no voltage present, check wiring.
If wiring is fine, replace transformer.
• Checking thermostat and its wiring.
Turn thermostat to call for heat.
(10 F above room
temperature).
* Put jumper between R and W terminals of aquastat
If boiler starts, check thermostat and thermostat wiring.
• Performing self diagnostics on aquastat.
* Check LED light on aquastat.
Light blinks 2x: check aquastat sensor contacts S1 and S2 and sensor wiring. If
it all looks fine, replace aquastat sensor.
Light blinks 3x or 4x: internal aquastat failure, replace aquastat
LED light off: aquastat is RESET mode, wait 5 minutes for automatic reset
Turn thermostat on aquastat to
call for heat (min. 10 °F above
boiler temperature).
Does fan motor starts?
NO
• Check for 24 V between terminals B1 and B2 of aquastat.
If no 24 V, replace aquastat.
• Checking the fan relay and the fan motor.
* Check for 24 V between terminals 1 and 4 of “terminal of boiler block“ strip
(“terminal strip“).
If no 24 V, check wiring between aquastat terminals B1/B2 and terminal strip.
If 24 V between terminal 1 and 4, check for 120 V between terminals L3 and N of
plug X3.
If no 120 V, check wiring between terminal strip and relay and between relay and
terminal plug X1 (incoming power).
If wiring is fine, replace relay.
If 120 V is present between terminals L3 and N of plug X3, check wiring of the fan
blower.
If wiring is fine: replace fan blower
We reserve the right to make any changes due to technical modifications!
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
45
12
Maintenance
Spark across ignitor/sensor gap
(look through sight glass)
NO
Checking the S 8600 ignition module.
• Check for 24 V between terminals 3 and 4 of the terminal strip.
(Power supply to S8600 ignition module)
If present:
• Check wiring between terminal strip and S8600 module.
• Check position of ignition cable plug on ignition sensor ceramic
insulator.
• Check ignition cable, ground wiring, ignition sensor ceramic
insulator and gap. Set gap to 3 - 4 mm. (1/8" to 1/6").
• Check boot of the ignition cable for signs of melting or
buckling.
• If everything checks okay, replace S8600 ignition module.
Checking the flame roll-out switch.
• Check for 24 V between terminals 2 and 3 of terminal strip.
If no 24 V present, check wiring between terminal strip and flame
roll-out switch. Check for continuity of flame roll-out switch.
If open circuit, replace flame roll-out switch.
Checking the pressure switch.
• Check for 24 V between terminals 1and 2 of terminal strip.
If no 24 V present, do following:
• Check wiring between pressure switch and terminal strip on boiler block.
• Check exhaust and air intake piping for blockage.
• Check air intake hose of boiler for blockage and ensure full
diameter.
• Check for blocked heat exchanger of the boiler.
• Check total length of exhaust and air intake piping versus
listed tables Table 7 to Table 9 on page 24 and page 25.
If everything checks okay: replace pressure switch.
Turn gas supply on.
Pilot burners lights.
NO
Checking gas valve and S 8600 module.
• Check that all manual gas valves are open, supply tubing and pressures
are good and pilot burner orifice is not blocked.
• Before first start-up, purge the air from gas supply pipe.
• Check electrical connections between module and pilot operator on gas
control.
• Check for 24 V across MV-MV/PV terminals on module. If voltage is fine,
replace gas control. If not, replace module.
We reserve the right to make any changes due to technical modifications!
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Maintenance
Sparks stops when pilot is lit.
12
NO
Checking S 8600 module
• Check continuity of L and N wiring on 120 V terminal.
• Check continuity ignition cable and ground wire.
• Check position of ignition cable plug on ignition sensor ceramic
insulator.
•
•
•
•
Check flame rod.
Check electrical connections between flame rod and module.
Check for cracked ceramic flame rod insulator.
Check that pilot flame covers flame rod and is steady and blue.
Adjust pilot flame.
• If problem persists, replace module.
Main burner lights.
NO
Checking gas valve and S 8600 module.
• Check for 24 V across MV-MV/PV terminals, closed ciruit on module.
If no voltage, replace module.
• Check electrical connections between module and gas control.
If okay, replace gas control.
Systems run until call for heat
ends.
NO
Checking S8600H module.
• Check continuity ignition cable and ground wire.
Note: If ground is poor or erratic, shutdowns may occur occasionally even
though operation is normal at the time of checkout.
• Check that pilot flame covers flame rod and is steady and blue.
• If checks are okay, replace module.
Call for heat ends, system shuts
off.
Troubleshooting ends
NO
Checking gas valve and S 8600 module.
• Check for proper thermostat (controller) operation.
• Remove MV lead at module.
• If valve closes, recheck temperature controller and wiring, replace module
• If valve does not close, replace gas control.
Repeat procedure until troublefree operation is obtained.
We reserve the right to make any changes due to technical modifications!
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
47
12
Maintenance
Thermostat (Controller) calls for heat
START
Stage 1
Trial for ignition
Fan motor starts operating.
Spark generator powered
• Pilot valve opens.
Pilot burner operation
Pilot burner light,S 8600 H senses
flame current.
or
Pilot burner does not light.
S 8600 H trial for ignition continues for
90 seconds and locks out.
If flame current sensed
• Spark generator off
Stage 2
• Main valve operator opens
Power interuptions
Main burner
operation
System shuts off. Restarts
when power restored?
Main burner operation
Pilot flame failure
• S 8600 H monitors pilot flame current
Main valve closes,
S 8600 H starts trial for
ignition.
Thermostat (controller) satisfied
Main and pilot valve close, burners shut off.
Fan motor is shut off.
END
We reserve the right to make any changes due to technical modifications!
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Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Parts List
13
13 Parts List
The following parts are directly available from Buderus
Hydronic Systems, Inc. Please use the listed description
and part number when ordering replacement
components.
Boiler block (Fig. 40)
Item.
Part description
No.
10
20
25
30
35
40
50
55
60
65
70
80
90
95
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
265
270
275
280
290
300
310
320
321
322
323
330
340
350
Non combustible base
Bottom support rail 386x54x65 left side
Bottom support rail 386x54x65 right side
Combustion chamber side plate 303x135 left
Combustion chamber side plate 303x135 right
Hex.-screw ISO4017 M8x100 8.8
Spring DIN128 A8 A3k
Washer DIN125 A8 A3k
Hex.-nut ISO4032 M8 8 A3k
Gasket D6x20x2 SIL24
Boiler feet
Return pipe R1 1/2xNpt11/2
Supply pipe R11/2xNpt11/2x3/4
Elbow 90° Nr92 NPT3/4
Relief valve Conbraco 30PS1
Snap nut 4,8 SNU2012
Rear insulation board
Sheet metal screw DIN7981 C ST4,8x22
Screw ST3,9x9,5 A3T
Temperature and pressure gauge
Cast iron boiler block
Chrome well (Npt)
Adapter 1-3/4"
Connection piece DIN2950 526 3/4"x80
Elbow
Air intake hose DN 100x690
Air intake hose clamp set 90-110x9
Flue gas blower box
Base plate for flue gas blower
Flue gas blower box cover plate
Hose set DN4x2x880 Silicone
Flange plate D87x140x2
Collar D79,5/D77/D75x160
Flange plate D140/D77
Flue gas fan motor 120V/60
Gasket D140xD72x5
Cover plate test-port fan blower
Pressure switch for flue gas blower
Pressure switch DL3ET-Z
Threaded bolt DIN 939 M8x30 5.6
Washer DIN 125 A8.4 A3k
Hex. nut ISO 4032 M8
Tube with sealant material for block assembly
PK-W11 310 ml
Silicone HT
Mounting Material for boiler block
6302563026979
63026980
63026977
63026978
Mounting Material
Mounting Material
Mounting Material
Mounting Material
Mounting Material
Mounting Material
5584754
5584752
99908401
5900076
Mounting Material
63026Mounting Material
Mounting Material
5900076
630265446190
3869828
320840
6302663026981
63026991
63026302630263016451
63028921
630263028858
63026836
63026837
63026838
63011683
6302Mounting Material
Mounting Material
Mounting Material
Model 37
Quantity
312
1
1
1
1
4
4
4
4
4
4
1
1
1
1
2
974
2
1
1
967
1
1
1
973
1
1
6831
6833
6834
1
1
6835
6836
1
1
1
6839
6
4
4
Model 44
Quantity
312
1
1
1
1
4
4
4
4
4
4
1
1
1
1
2
974
2
1
1
967
1
1
1
973
1
1
6832
6833
6834
1
1
6835
6836
1
1
1
6840
6
4
4
Model 53
Quantity
313
1
1
1
1
4
4
4
4
4
4
1
1
1
1
2
975
2
1
1
968
1
1
1
972
1
1
9098
9097
9096
1
1
9099
8856
1
1
1
9100
6
4
4
Model 62
Quantity
314
1
1
1
1
4
4
4
4
4
4
1
1
1
1
2
976
2
1
1
969
1
1
1
971
1
1
8849
8853
8855
1
8857
1
8856
1
1
1
8839
6
4
4
2037038
1
1
1
1
63000116
63026970
1
1
1
1
1
1
1
1
Buderus
Part number
Table 14 Boiler block
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
49
13
Parts List
250
280
300
310
240
320
265
270
260
275
290
140
140
230
220
210
150
80
160
100
140
90
140
220
95
130
30
322
323
120
323
170
180
190
321
110
321
322
323
140
35
40
20
70
25
321
330
140
322
323
321
340
200
322
323
10
65
55
50
60
1021933-02-Kesselblock GA244 "US/CA"
Fig. 40
Boiler block
We reserve the right to make any changes due to technical modifications!
50
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Parts List
13
Boiler Jacket Panels (Fig. 41)
Item.
Part description
No.
Buderus
Part number
Model 37
Quantity
Model 44
Quantity
Model 53
Quantity
Model 62
Quantity
10
Name plate
63025232
1
1
1
1
20
Edge protection set
63020896
1
1
1
1
30
Middle panel
63025-
238
238
239
240
40
Boiler block insulation
63025-
233
233
234
235
50
Rear panel
63025-
229
229
230
231
60
Top rear cover panel
63025-
226
226
227
228
225
70
Top front cover panel
63025-
223
223
224
80
Front panel (delivered until February 2004)
63025-
220
220
221
222
80
Front panel (delivered from March 2004)
63028-
708
708
709
710
90
Side panel left (delivered until February 2004)
63025219
1
1
1
1
90
Side panel left (delivered from March 2004 )
63028706
1
1
1
1
100
Side panel right (delivered until February 2004)
63025218
1
1
1
1
100
Side panel right (delivered from March 2004)
63028705
1
1
1
1
110
Right side panel cover plate (delivered until February 2004)
63026310
1
1
1
1
110
Right side panel cover plate (delivered from
March 2004)
63028711
1
1
1
1
120
Sheet metal screw C St3.9x50
Mounting Material
20
20
20
20
130
Snap nut
Mounting Material
2
2
2
2
140
Clip spring
476378
5
5
5
5
63025389
1
1
1
1
-
Mounting material for boiler jacket
Table 15 Boiler jacket
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
51
13
Parts List
60
120
65
70
120
120
120
50
140
120
40
120
90
120
120
30
20
Bu
de
rus
GA
24
120
4
10
130
80
100
120
110
120
120
120
120
1021934-02-Verkleidung GA244 "US/CA"
Fig. 41
Boiler jacket panels
We reserve the right to make any changes due to technical modifications!
52
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Parts List
13
Measuring Line - Set (Fig. 42)
Item.
Part description
No.
10
Measuring line set CE244
Buderus
Part number
Model 37
Quantity
Model 44
Quantity
Model 53
Quantity
Model 62
Quantity
6302-
5822
5822
5822
5822
The measuring line set contains the following components:
20
Pressure measuring orifice G1/8" (DIN288-1)
0548-
1194
1194
1194
1194
30
Gasket ringDIN7603 A 10x13,5x1,5 Cu
6301-
5874
5874
5874
5874
40
Hex.-nut G1/8"
2
2
2
2
50
Pressure measuring orifice G1/8"
1
1
1
1
60
Silicone hose 3x1,5x120mm
1
1
1
1
70
Pressure measuring orifice 394537
1
1
1
1
Table 16 Measuring line set
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
53
13
Parts List
10
40
30
20
30
50
60
Fig. 42
Measuring line set
We reserve the right to make any changes due to technical modifications!
54
70
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Parts List
13
Control panel GAW028 (Fig. 43)
Item.
Part description
No.
Buderus
Part number
Model 37
Quantity
Model 44
Quantity
Model 53
Quantity
Model 62
Quantity
-
63026298
63026298
63026299
63026300
63015750
1
1
1
1
10
Control panel GAW 028 00 compl. "US"
20
Relay 24V AC 1xS 120V AC/15A
30
Sheet metal screw DIN7981 F ST3,5x6,5 A3
see mounting-material for GAW027/GAW028 „US“
40
Terminal strip 4 qmm 4-pin
see mounting-material for GAW027/GAW028 „US“
50
Sheet meatl screw DIN7981 F ST3,5x16 A3K
see mounting-material for GAW027/GAW028 „US“
60
Middle panel GA244 "US"
70
Ignition module S 8600H1006
80
Screw ST3,9x9,5 A3K
90
Cover plate for ignition module GAW028 "US"
see boiler jacket
1
1
1
1
63015743
1
1
1
1
see mounting-material for GAW027/GAW028 „US“
63026301
1
1
1
1
100
Tooth lock washer DIN6797 A4,3 A3K
see mounting-material for GAW027/GAW028 „US“
110
Hose AWG 2x18 063/076
63015745
1
1
1
1
120
Cabling tree GAW 022/024/026/027
63015746
1
1
1
1
130
Temperature sensor 32004955-003B
63015749
1
1
1
1
140
Blank piece für 1/4 ciruit sensor
07060110
2
2
2
2
150
Distance spring
05446800
1
1
1
1
160
Sensor bracket
07060986
1
1
1
1
170
Transformer 120V/24V "US" compl.
63015748
1
1
1
1
180
Aquastat Relay L7148F
63015742
1
1
1
1
190
Sheet metal screw DIN7981 C ST3,5x25 A3K
200
Interconnecting cable
210
Sheet metal screw DIN7981 C ST2,9x16 A3K
220
3-pin plug black 93.923.4354
05493464
1
1
1
1
230
3-pin female connector black 93.031.3253.0
07060911
1
1
1
1
240
3-pin plug green/black
05493465
1
1
1
1
250
3-pin female connector green
07060912
1
1
1
1
260
Sheet metal screw DIN7981 C ST2,9x25 A3K
270
5-pin female connector black
280
Sheet metal screw DIN7981 F ST3,5x9,5A3K
see mounting-material for GAW027/GAW028 „US“
63015744
1
1
1
1
see mounting-material for GAW027/GAW028 „US“
see mounting-material for GAW027/GAW028 „US“
07060913
We reserve the right to make any changes due to technical modifications!
1
1
1
1
see mounting-material for GAW027/GAW028 „US“
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
55
13
Parts List
Control panel GAW028 (Fig. 43)
Item.
Part description
No.
Mounting-material for GAW027/GAW028 „US“
Buderus
Part number
Model 37
Quantity
Model 44
Quantity
Model 53
Quantity
Model 62
Quantity
63015810
The mounting material contains the following components:
30
Sheet metal screw DIN7981 F ST3,5x6,5 A3
10
10
10
10
40
Terminal strip 4 qmm 4-pin
1
1
1
1
50
Sheet metal screw DIN7981 F ST3,5x16 A3K
5
5
5
5
80
Screwe ST3,9x9,5 A3E
5
5
5
5
100
Tooth lock washer DIN6797 A4,3 A3K
5
5
5
5
190
Sheet metal screw DIN7981 C ST3,5x25 A3K
5
5
5
5
210
Sheet metal screw DIN7981 C ST2,9x16 A3K
5
5
5
5
260
Sheet metal screw DIN7981 C ST2,9x25 A3K
4
4
4
4
280
Sheet metal screw DIN7981 F ST3,5x9,5A3K
2
2
2
2
Tab. 17 Control panel GAW028
We reserve the right to make any changes due to technical modifications!
56
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Parts List
13
10
20
30
30
40
50
50
270
240
60
260
250
230
210
200
210
220
280
170
100
30
100
80
30
80
180
70
80
190
80
190
190
160
140
190
150
100
130
30
90
30
110
100
100
30
120
100
30
Fig. 43
Control panel GAW028
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
57
13
Parts List
Burner Tray Assembly (Fig. 44)
Item.
Part description
No.
Buderus
Part number
Model 37
Quantity
Model 44
Quantity
Model 53
Quantity
Model 62
Quantity
6302-
5795
5795
5796
5797
10
Burner tray assembly CE244 compl.
20
Gasket for burner tray assembly
30
Secondary air guide plate
40
Lens screw DIN7985-M4x20-5.8-A3K
0588-
3286
3286
3286
3286
50
Flame roll-out switch 377Grad f
0047-
1336
1336
1336
1336
60
Screw DIN7500 CE M5x12 CombiTorx
15 pieces/set
6302-
8938
8938
8938
8938
70
Burner tray cover plate CE244 5Gld compl. "US"
6302-
5808
5808
5809
5810
80
Bottom - gasket for burner tray cover plate
Gasket set
90
Top - gasket for burner tray cover plate
Gasket set
100
Observation port compl.
0710-
0256
0256
0256
0256
110
Screw St3,9x9,5 A3T
0594-
7754
7754
7754
7754
120
Gasket - Set for burner tray assembly CE244
5 section compl.
6302-
5925
5925
5926
5927
130
Clue Elastosil E 41 in 90ml tube
6301-
1270
1270
1270
1270
Gasket set
Table 18 Burner tray assembly
We reserve the right to make any changes due to technical modifications!
58
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Parts List
13
10
100
50
40
90
90
20
30
60
100
80
110
70
120
90
20
80
90
130
1021797-01-Gehäuse für Brenner CE244 "US"
Fig. 44
Burner tray assembly
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
59
13
Parts List
Gas Valve VR8304 (Fig. 45)
Item.
Part description
No.
Buderus
Part number
Model 37
Quantity
Model 44
Quantity
Model 53
Quantity
Model 62
Quantity
10
Gas supply pipe CE244 compl. "US"
with sleeve nut and gasket
6302-
5807
5807
5807
5807
20
Sleeve nut G 1 1/4
0518-
1564
1564
1564
1564
30
Gasket D27x38x2mm C4400 Klinger SIL, green
0548-
9356
9356
9356
9356
40
Socket with Flange 25,4x25,4 compl.
with O-ring gasket and Screws
6302-
5821
5821
5821
5821
50
Screw 8x32x1/2
60
O-ring gasket 24, 2x3 PERBUNAN
6302-
5931
5931
5931
5931
70
VR8304 gas valve, complete w/ O-Ring, pressure
tap and screws
6302-
5794
5794
5794
5794
80
Pressure measuring orifice 394537
90
Screw - Set gas valve VR8304 compl.
5928
5928
5928
5928
100
Screw 8x32x11/4 A3T
s. Screw Set
Gas valve VR8304
s. pressure
measuring set
CE244
6302s. Screw Set
Gas valve VR8304
Table 19 Gas valve VR8304
We reserve the right to make any changes due to technical modifications!
60
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Parts List
13
10
20
30
20
30
50
60
40
50
60
70
50
60
80
100
80
100
50
90
Fig. 45
Gas valve VR8304
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
61
13
Parts List
Pilot burner, Pilot gas line (Fig. 46)
Item.
Part description
No.
Buderus
Part number
Model 37
Quantity
Model 44
Quantity
Model 53
Quantity
Model 62
Quantity
10
Pilot burner Q381 A compl. with pilot orifice, union
and screws
6302-
5819
5819
5819
5819
20
Screws DIN7500 CE M5x12 CombiTorx
15 pieces/set
6301-
0217
0217
0217
0217
40
Pilot gas orifice for natural gas 390686-37
6302-
4518
4518
4518
4518
40
Pilot gas orifice for propane gas 390686-61
6302-
6339
6339
6339
6339
50
Pilot burner union D4
0518-
1672
1672
1672
1672
60
Pilot gas line CE244 5/7Gld. compl. "US" with union and grommet
6302-
5817
5817
5818
5818
70
Grommet D68/D60/D48/D22
80
Ignition cable KD7 SD6,3 S6,3x0,8 HF compl.
with grommet
5820
5820
5820
5820
90
Grommet DV 4/9
s. grommet Set
CE244
100
Cable fastener 2,5x92
s. grommet Set
CE244
110
Grommet Set CE244 compl. "US"
5823
5823
5823
5823
s. grommet Set
CE244
6302-
6302-
Table 20 Pilot burner, pilot gas line
We reserve the right to make any changes due to technical modifications!
62
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Parts List
13
90
100
80
20
20
40
50
10
40
50
70
60
110
50
70
90
100
Fig. 46
Pilot burner, pilot gas line
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
63
13
Parts List
Burner tray assembly (Fig. 47)
Item.
Part description
No.
Buderus
Part number
Model 37
Quantity
Model 44
Quantity
Model 53
Quantity
Model 62
Quantity
10
Burner bar assembly CE 244 compl. "US
with main orifices for Natural gas (G20) 0-2000FT
6302-
5802
5803
5804
5804
20
Insulation CE244 5 section compl. "US"
6302-
5811
5811
5812
5813
30
Ceramic clue Thermofix Tube 115gr.
0203-
7312
7312
7312
7312
40
Manifold CE244 5 section compl. "US"
6302-
5814
5814
5815
5816
50
Screw 8x32x1/2
s. Screw Set
VR8304
60
Screw 8x32x11/4 A3T
s. Screw Set
VR8304
70
Grommet D68/D60/D48/D22
80
Screw DIN7500 CE M5x12 CombiTorx
15 pieces/set
6301-
0217
0217
0217
0217
90
Gasket 13x18x1,5mm
0588-
3094
3094
3094
3094
100
Main orifice 3,00 mm SW16 16mm long
4 pieces
0548-
100
Main orifice 3,25 mm SW16 16mm long
4 pieces
0548-
7620
7620
7620
7620
110
Sight glas Tempax 30x30x3,3mm
0544-
5802
5803
5804
5804
s. Grommet Set
CE244"US"
Table 21 Burner tray assembly
We reserve the right to make any changes due to technical modifications!
64
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Parts List
13
10
20
30
110
100
90
80
80
40
70
60
50
Main gas orifices
Fig. 47
Model/
section
Orifice/
gasket
Sea-level in FT
37/5
37/5
37/5
37/5
44/5
44/5
44/5
44/5
53/6
53/6
53/6
53/6
62/7
62/7
62/7
62/7
4/4
4/4
4/4
4/4
4/4
4/4
4/4
4/4
5/5
5/5
5/5
5/5
6/6
6/6
6/6
6/6
0-2000
2001-4500
4501-6000
6001-8000
0-2000
2001-4500
4501-6000
6001-8000
0-2000
2001-4500
4501-6000
6001-8000
0-2000
2001-4500
4501-6000
6001-8000
Type of gas in mm
Natural gas (G20) Propane (G31)
3,00
2,85
2,75
2,60
3,25
3,05
2,95
2,80
3,20
3,05
2,95
2,80
3,15
3,00
2,90
2,75
1,95
1,85
1,80
1,70
2,15
2,05
1,95
1,85
2,10
2,00
1,90
1,85
2,20
2,10
2,00
1,90
1021794-01-Burner bar assembly CE244 "US"
Burner tray assembly
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
65
13
Parts List
NOTICE!
The boiler is factory set for operation with
natural gas at elevations up to 2000 ft.
The boiler must be derated for installations
above 2000 ft. The derate is accomplished
by changing the main burner orifices.
Contact Buderus in this case to obtain the
suitable high elevation conversion kit.
Types of Burners, Conversion Kits (Fig. 48)
Buderus
Part number
Model 37
Quantity
Model 44
Quantity
Model 53
Quantity
Model 62
Quantity
6302-
5798
5799
5800
5801
Gas conversion kit for propane CE244 G31
0-2000FT "US"
630-
26333
26334
30003
26336
Gas conversion kit for propane CE244 G31
2001-4500FT "US"
630-
27390
27393
30004
28910
Gas conversion kit for propane CE244 G31
4501-6000FT "US"
630-
27391
27394
30005
28911
Gas conversion kit for propane CE244 G31
6001-8000FT "US"
630-
27392
27395
30006
28912
Gas conversion kit for natural gas CE244 G20
0-2000FT "US"
630-
25921
27396
29999
28913
Gas conversion kit for natural gas CE244 G20
2001-4500FT "US"
630-
25922
27397
30000
28914
Gas conversion kit for natural gas CE244 G20
4501-6000FT "US"
630-
25923
27398
30001
28915
Gas conversion kit for natural gas CE244 G20
6001-8000FT "US"
630-
25924
27399
30002
28916
Item.
Part description
No.
10 Gas burner CE244 Gr.37/5 G20 compl. "US"
Table 22 Types of burners, Gas conversion kits
We reserve the right to make any changes due to technical modifications!
66
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Parts List
13
10
Leistung
37 kW
Ser.-Nr. 63023412-00-3253-000001
00000001
The rating label is placed on the left side of the burner box.
Fig. 48
Burner tray assembly, Gas conversion kits
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
67
14
Orifice Tables for High Elevations and Propane
14 Orifice Tables for High Elevations and Propane
Orifice Table for Natural Gas and High Elevations
Boiler
model
Orifice Size (mm) for different Elevations
[feet]
No. of
Orifices
Manifold
Pressure
[in. W.C.]
0–2000 ft
2001–4500 ft
4501–6000 ft
6001–8000 ft
37
4
3.00
2.85
2.75
2.60
3.77
44
4
3.25
3.05
2.95
2.80
3.65
53
5
3.20
3.05
2.95
2.80
3.73
62
6
3.15
3.00
2.90
2.75
3.77
Table 23 Main orifice sizes and high elevations for natural gas
Orifice Table for Propane Gas and High Elevations
Boiler
model
Orifice Size (mm) for different Elevations
[feet]
No. of
Orifices
Manifold
Pressure
[in. W.C.]
0–2000 ft
2001–4500 ft
4501–6000 ft
6001–8000 ft
37
4
1.95
1.85
1.80
1.70
8.03
44
4
2.15
2.05
1.95
1.85
7.63
53
5
2.10
2.00
1.90
1.85
8.11
62
6
2.20
2.10
2.00
1.90
6.15
Table 24 Main orifice sizes and high elevations for propane gas
Spare part numbers for orifices
Part description
Buderus
Part number
Remark
Part description
Buderus
Part number
Main orifice 1,70 mm
63029151
Main orifice 2,75 mm
63029149
Main orifice 1,80 mm
63029387
Main orifice 2,80 mm
63029403
Main orifice 1,85 mm
63029152
Main orifice 2,85 mm
63029150
Main orifice 1,90 mm
63030022
Main orifice 2,90mm
63030025
Main orifice 1,95 mm
63029146
Main orifice 2,95mm
63029404
Main orifice 3,00mm
63029145
Vtolerance 2%
SW16
Length 16 mm
Main orifice 2,00 mm
63030023
Main orifice 2,05mm
63029401
Main orifice 3,05mm
63029405
Main orifice 2,10 mm
63030024
Main orifice 3,15 mm
63029406
Main orifice 2,15 mm
63029402
Main orifice 3,20 mm
63029188
Main orifice 2,20 mm
63030241
Main orifice 3,25 mm
63029147
Main orifice 2,60 mm
63029148
We reserve the right to make any changes due to technical modifications!
68
Remark
Vtolerance 2%
SW16
Length 16 mm
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Wiring diagrams
15
15 Wiring diagrams
Fig. 49
Wiring diagram– GA244 model
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
69
15
Fig. 50
Wiring diagrams
Wiring diagram– GA244 model
We reserve the right to make any changes due to technical modifications!
70
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
Wiring diagrams
Fig. 51
15
Wiring diagram – GA244 with control panel Logamatic 2107 or Logamatic 2109
We reserve the right to make any changes due to technical modifications!
Buderus Heiztechnik GmbH • http://www.heiztechnik.buderus.de
Installation, Operation and Maintenance Manual Sealed Combustion Gas Boiler Logano GA244 • Issue 02/2004
71
Heating Contractor:
PRODUCTS MANUFACTURED BY
BBT Thermotechnik GmbH
35573 Wetzlar
www.buderus.de
BBT North America Corporation
50 Wentworth Avenue
Londonderry, NH 03053
Tel: 603-552-1100 ● Fax: 603-584-1681
www.buderus.net
BBT North America Corporation reserves the right to make changes without notice
due to continuing engineering and technological advances.